CONTENTS SECTION 1 GENERAL INFORMATION 1.0 Introduction 1.1 General description 1.2 Technical data 1.3. Weight list 2.4 O41 specification 1.5 The actuator 1.6 The pump unit 2.7 Functioning of the pump/control unit 1.8 Functioning of the actuator 1.9 Storing of the equipment and filling of oil SECTION 2 INSTALLATION - COMMISSIONING - SEA TRIAL 2.0 Installation 2.1 Mounting/dismounting rudderstock 2.2 Filling of oil and venting procedure 2.3 Procedure for start-up and sea-trial SECTION 3 MAINTENANCE INSTRUCTION 3.0 Service locations 1 Maintenance reporting 2 Maintenance 3 Periodical maintenance 4 3 3. 3 3 Cleaning the strainer/filter of the pump unit SECTION 4 REPAIR INSTRUCTION 4.0 Fault finding chart 1 Renewal of the actuator seals +2 Control and renewal of the trustbearing 3 Control and renewal of the liners 4 Pump unit SECTION 5 DRAWINGS 5.0 Drawing list SECTION 6 PARTS CATALOGUE 6.0 Parts list - Actuator and Pump unit BeBe Vana aauE 18 20 22 23 26 27 28 29 30 32 33 35 36 37 39 42SECTION 1 GENERAL INFORMATIONSECTION 1.0 InrRopucrron This instruction manual, issued for Frydenbo rotary vane rudder actuator, is prepared for use by the operating personnel. The operators should familiarize themselves with the working principles of the equipment and with the instructions and Precautions contained herein. The manual should be kept handy for reference at all times so that the proper and correct operating instructions can be observed and followed. No dismantling or adjusting work should be started unless the pertinent instructions have been carefully studied so that the work sequence is clear and all of the necessary tools are available. it is of paramount importance that extreme cleanliness is obsexved during all work on the equipment. Sand, dust, or other impurities are detrimental to the hydraulic equipment and will most likely impair the proper operations. Keep hands and tools clean. Use only clean linen rags, - never cotton waste. Frydenbo-Mjolner is ready to be of assistance and service at all times and will appreciate the operator’s comments on any phase of the equipment’s operation and it’s maintenance.PE SECTION 1.1 GENERAL DESCRIPTION (See general arrangement dwg.) A. STEERING GEAR The FRYDENB@ steering gear on this vessel is composed of one hydraulic rotary vane actuator mounted directly on the rudder stock, served by two pump units delivering the necessary oil pressure for operating the rudder. The two pump units may be operated together or separately. When cruising at sea, only one pump unit is normally in operation while the other is acting as a stand-by unit. | During manoeuvering of the vessel, when the shortest possible steering time is required, it is possible to run both pump units simultaneously whereby the rudder rate will be doubled. The pump units are equipped with solenoid valves, which are normally operated by means of signals from the bridge steering controls. The expansion tank keeps a head pressure to the suction side of pump. The tank is divided into two chambers, one for each pump unit, with one low level alarm-switch in each of the chambers. From top of the steering gear leakage oil will run through pipe to the expansion tank.SECTION 1.2 TECHNICAL DATA 1) 2) 3) 5) RUDDER ACTUATOR Type Rudderstock diameter Maximum rudder angle Maximum oil pressure Relief valve setting Design torque Displacement (35-0-30) = 65 degr Steering time (35-0-30) degr. with one pump running Steering time (35-0-30) degr. with two pumps running PUMP UNIT Type Screw pump "Allweiler" type Revolution Capacity at 1750 R.P.M Relief valve setting Maximum temperature system Solenoid valve ELECTRIC MOTOR Type Rating Voltage current Frequency Protection degree Revolution CAPACITY TOTAL FOR ONE SYSTEM Rudder actuator Pump unit Expansion tank Pipe lines / hoses Total oil volume HS 280-03 390 mm 2.x 37,5 degr. 75 BAR 75 BAR 952 kNm 144 liters max. 28 seconds max. 14 seconds PE 2" SNE 280 ER 46 1750 R.P.M. 330 1/min 75 Bar 70 degr.c. Bosch 96 V SIEMENS 180L 25 kW 3x 440 VAC 42.0 60 Hz IP 54 1750 R. 250 Liters 50 Liters 60 Liters —50.Liters 410. LitersSECTION 1.3 WEIGHT LIST STEERING GEAR TYPE HS 280-03 EQUIPMENT. WEIGHT BACH SYSTEM DRY Rudder actuator 4000 kg Pump unit 560 kg Expansion tank 55 kg TOTAL 4615 kgNoe SECTION 1.4 OIL SPECIFICATION HYDRAULIC OIL TYPE FOR ER ROTARY VANE STEERING Use only a high quality hydraulic oil with a viscosity index of 68. The oil should have anti-foam, anti-oxidant and anti-rust additives. OIL SPECIFICATION Viscosity: Iso 68 Oil temperatures should be limited to 70% The oil to be checked regularly for contamination, and the oil companies’ recommendation for change of oil to be followed. ©i1 level should be checked daily with new oil added as necessary.SECTION 1.5 THE ACTUATOR 1 The actuator consists of these main components: 1. Housing 2. Cover 3. Rotor 4. Stoppers 5. Vanes 6. Safety relief valveSECTION 1.5 THE ACTUATOR (Continued) LOCK VALVE The automatic lockvalve mounted on the actuator consists of a housing, where both pipes from the pump unit are connected Between inlet and outlet there is a pilot-piston which operates the two spring-loaded valves. RUDDER CASE 1 stock STEERING TAKES PLACE ROTOR Oil pressure from the pump unit opens both a the inlet and the outlet side of the valve. ACTUATOR Ol. PRESSURE FROM PUMP UNIT CASE 2 THE ACTUATOR CLOSED- RUDDER BLOCKED When there is no oil supply, the valves are kept closed by spring load. (Oil pressure inside the actuator will increase the closing force)SECTION 1.5 THE ACTUATOR 3 (Continued) SAFETY VALVE Theze is one safety valve-block on the actuator consisting of: - Pilot relief valve. Pilot piston. : Check valve. Springloaded main valve. Adjusting screw for relief pressure. uewee NORMAL RUNNING CONDITION: CASE 1: The working pressure, Pi, opens the check valve, 3, and will keep the safety valve in closed position. SAFETY VALVE OPENS: CASE 2: If the pressure increases to maximum, P2, which is the opening pressure for the pilot relief valve, 1, the springloaded main valve, 4, will be pushed over and the maximum pressure will be relieved over to the suction side. 0 GR a7 ACTUATOR ACTUATOR RETURN SIDE PRESSURE SIDE 10SECTION 1.6 THE PUMP UNIT PE-2 The pump unit consists of following components mounted on a common bedplate: . Pump housing. Built-in hydraulic screw pump cartridge. Full flow strainer. Safety relief valve. + Main control valve. Solenoid operated pilot valve for connection to steering controls, with emergency push-button steering controls. 7. Flexible coupling between motor and pump. 8. Electric motor. 2 1 aueenE L Pressure gauge. 0. Bedplate. aPE SECTION 1.7 FUNCTIONING OF THE PUMP/CONTROL UNIT The steering gear is nomally operated from the steering controls initiating the pilot valve solenoids. For emergency operation, the pilot valves are equipped with push button controls which make it possible to operate the steering gear manually from the steering gear compartment. CONTROL UNIT: 1. Solenoid - Pilot valve. 2. Safety relief valve. 3. Control valve. 4. Non-return valve. 70 actusToR or FIG. 1. IDLING: Fig.1 shows the pump unit when idling. The control valve, 3, and the solenoid valve, 1, are kept in center position by Spring load when no steering signal is given. 12SECTION 1.7 ICTIONING OF THE PUMP/CONTROL UNIT PE (Continued) FIG. 2. STEERING: Steering is carried out by operating the solenoid valve (1). Fig.2 shows the steering process when the right solenoid is operated. The pilot valve (1) will be pushed over to the left side. The two control valve spindles, 3, are now forced against each other and held in the right hand position by the oil pressure in the left chamber. The oil-flow from the pump has now free passage from channel (1) into pipe (B) leading to the actuator. The return oil from the actuator flows through pipe (A) and has free passage to channel (2) and back to the suction side of the pump. 13SECTION 1.7 FUNCTIONING OF THE PUMP/CONTROL UNIT pp (Continued) FIG. 3. RELIEF VALVE (Item 2) When the oil pressure, C, exceeds the preset value of the valve spring load, the valve, 5, will open (fig 3). The pressure oil (D) will flow to channel (2), the pressure in the control valve end-chamber will drop and the spool will move to center position. The pressure oil from the pump will force the two valve spool halves (3) apart thus allowing the oil to flow through the internal boring to the return channel(2), see fig.1. SETTING THE RELIEF VALVE. (Item 2) Opening pressure for relief valve, see technical data sheet. To increase the pressure, turn adjusting screw, 6, clockwise. Safety valve opening pressure has been set during assembly by the suppliers and possible adjustment should only be carried out by @ competent person. EMERGENCY OPERATION During emergency operation the solenoid valves (1) can be manually operated by means of manual controls on the solenoid valve: NOTE: "Local/Remote"- switch, S3, on starter cabinets, has to be in local position during emergency operation. Use handle attached to the pump unit to operate the manual controls. EMERGENCY MAUAL CONTROLS D J sone hp ‘eee to 14SECTION 1.8 | FUNCTIONING OF THE ACTUATOR (See assembly dwg. of actuator) The actuator consists of three main components: A cylindrical housing with stoppers, a rotor and a bolted-on cover. The rotor, turning in bearings at top and bottom, is equipped with vanes upon which the oil pressure is acting and thereby developing the turning torque. The turning movement is limited by stoppers fixed to the housing. The stoppers also act as mechanical rudder stops in hard-over position. The axial bearing thrustring of the actuator is of sufficient capacity to carry the full weight of rudder, rudderstock and rotor, eliminating the need for a separate rudder carrier bearing. In’ addition to the stoppers, the actuator is equipped with electrical limit switches stopping the turning movement at the predetermined angle. The sealing system consists of synthetic oil resistant material resting in seal grooves, preventing effectively internal leakages, and gland seals preventing external leakage. The bearings of the actuator are lubricated by means of the system oil. AUTOMATIC LOCK VALVE The actuator is equipped with automatic lock valves. If there should be loss of oil pressure due to possible external failures, the lock valve will close immediately and keep the actuator intact for operation by means of the stand-by pump. SAFETY VALVE The actuator is equipped with a safety valve, limiting the pressure to the specified value. 15SECTION 1.9 STORING OF THE EQUIPMENT AND FILLING OF OIL. In order to protect the inside of the steering gears, a special corrosion retarding ingredient is added to the hydraulic oil used during final testing of the steering gear. This is a short time protection only. The steering gear should be filled with oil immediately after recieved at yard, to protect the equipment. PROCEDURE FOR FIL} ACTUATOR THE UNIT WITH OIL. Locations of filling- and drain plugs are marked on the arrangement drawing. l Open all bleeding plugs on top of the rudder actuator and the pump unit (See venting procedure section 2.2). 2. Use pump or gravity connected to the filling holes, to £111 the actuator and the pump. (See sketch). “NOTE: Fill oil through all filling plugs in order to fill all chambers of the actuator. USE PUMP OR joRAVITY Ei BLEEDING Zt PLUGS BLEEDING PLUGS BLEEDING PLUGS: FILLING PLUGS 16SECTION 2 INSTALLATION COMMISSONING- SEA TRIALPE SECTION 2.0 INSTALLATION RUDDER ACTUATOR Sufficient space for inspection and service of the gland seals must be provided (see arr. dwg). There should be sufficient space between top of the rudder actuator and-the deck above to pezmit the cover and the rotor to be lifted. If this cannot be arranged, a hatchway in deck may be provided. Tackle bracket should be arranged. Do, not open the rudder actilator during. installation. Forward position is marked on the actuator flange. 0-position of rotor is marked on top of the actuator. See arrangement drawing Make sure that rudderstock and actuator are aligned. For fastening of the rudderstock to the rudder actuator, see “Procedure for mounting/dismounting of the rudder actuator on the xudderstock", section 2.1. EXPANSION TANK : aD The expansion tank to be installed as close as possible to the suction side of both pumps, and with the connecting pipes having & continous slope ensuring free flow to the suction side of both pumps, even at max. healing (See arr. dwg.) . 18PE SECTION 2.0 INSTALLATION (Continued) PUMP_UNT: The pump unit should be installed close to the rudder actuator with good access for inspection and maintenance. CHECK ALIGNMENT El.motor and pump are aligned when delivered from Prydenbo. After fastening bedplate, the alignment between the el. motor and the pump should be checked. Measure distance A with ruler and B with feeler gauge on several points on the periphery of the coupling as shown on the fig. If there is a difference of more than 0.2 mm, mount shims under fastening bolts for the el.motor until the pump unit is aligned. FEELER GAUGE c RULER PIPES . Sharp vertical bends on the pipe lines should be avoided, as air pockets may occur. 19‘ae? SECTION 2.1-1 PROCEDURE FOR HYDRAULIC MOUNTING SMOUNTING OF THE RUDDER ACTUATOR ON THE RUDDERSTOCK. The taper area of the rudderstock should be adapted to the rudder actuator, use blue colour, until sufficient contact between the Fudder stock and the rotor has been obtained (according to classification requirements) . See drawing and table "HYDR.MOUNTING / DISMOUNTING OF RUDDERSTOCK", fig.1. NECESSARY EOUIPMENT: 2 High pressure oilpumps with pressure gauges, min 1000 bar. 1 Dial gauge. OIL SPECIFICATION: Hydraulic oil: 100 mm2/s at 40 °c. MOUNTING. 1. Clean and lubricate the taper area of the rudderstock and the rotor. 2. Put the rudder actuator on the rudderstock with it’s full weight on the taper area. 3. Mount the hydraulic nut and tighten by hand. 4. Mount pump 1 for oil pressure to the nut, and pump 2 for oil pressure to the taper. 5. To find a correct starting position for the pull up length, start to pump oil into the nut with pump juntil the pressure starts to increase (max. 50 bar) Relieve the pressure and tighten the nut until contact between nut and actuator is obtained. This to avoid that the o-ring on piston in the nut should break if too long stroke. (For permissable length of stroke, see arrangement drawing.) This is the starting position 6. Mount the dial gauge and adjust to zero. 20SECTION 2.1-2 PRO FOR HYDRAULIC M¢ DISMOUNTING (Continued) QF THE RUDDER ACTUATOR ON THE RUDDERSTOCK. 7. Pump oil (pump 2) to the taper fitting until the oil leaks out at the lower part of the taper. 8. Increase slowly the pressure from both pumps 1 and 2 until the rudderstock is pulled up the length "L", specified in the table. NOTE: When pulling up, keep pressure as high as possible on pump 2. (Until the oil leaks out at the lower part of the taper). mor Relieve the pressure from pump 2. 10. Wait about 30 minutes, and then relieve the pressure from pump 1. 21. Check the length "L". 12. Dismount the pumps and the dial gauge. 13. Tighten the nut to contact with the actuator. 14. Secure the rudderstock nut. ISMOUNTING 1 Dismount the lockplate. 2 Unscrew the nut to the length (L + 2) mm. See the table. 3. Mount pump 1 for oil pressure to the nut, and pump 2 for oil-pressure to the taper. a. Increase the oil-pressure from pump 1 to about 50 bar. 5 Increase the pressure on the taper (pump 2) gradually until the pressure in the nut (pump i) is rising. This indicates that the taper is "floating". 6. Reduce the pressure from pump 1 gradually without reducing the taper pressure (from pump 2), and the rudderstock will be released from rudder actuator. 22SECTION 2.1-3 PROCEDURE FOR ULIC_MOUNTIN¢ (Continued) OF RUDDER ACTUATOR ON THE RUDDERSTOCK. MOUNTING OF RUDDERSTOCK DISMOUNTING PULL UP PULL UP LENGTH: PISTON AREA: PISTON STROKE: RUDDERSTOCK DIA. CALCULATION NO. 1 PUMP 2 8,4 MM 712 cw 14 MM 390 MM 2058 24 FIG 1.PE SECTION 2.2 EILLING OF OIL AND VENTING PROCEDURE To £111 actuator and Pump unit with oil, see section 1.11. Oil specification, see section 1.4. Before starting to £ill oil, open all vent plugs on the actuator and the pump units. Fill oil into the expansiontank. Bump_unit fo F411 the pump units open valves item 21 and 22. The oil will flow into the pump units. When the oil flows out of the vent plugs without air bubbles, close the vent plugs. tis important to keep the expansion tank filled with oil during the whole operation. Actuator Now stazt the pump units (check the correct rotation). operate the solenoid valves manually for a few seconds, to move the rudder. Stop the pumps immediately if hearing cavitation sound. Wait until oil from the expansion tank fills up the suction side of the pump again. Meanwhile do the same operation on the second pump unit. Repeat this procedure until the actuator is filled up with oil, and vent the system. Vent: edu Start the pump units. Operate the solenoid valves manually to move the rudder. stop the Pumps and vent the system. Start again and move the rudder hard-over to hard-over. The system should now operate smoothly without noise. If still noisy, repeat the venting. aetten XDRAULIC SYSTEM IS TO BE RELIABLE AND FUNCTION SATISFACTORILY, ALL AIR MUST BE REMOVED FROM THE SYSTEM. 22SECTION 2.3 PROCEDURE FOR START-UP AND SEA TRIAL START-UI Fill oil into the actuator and the pump unit according to instruction, and bleed the system. ~ Control that the electric motor is rotating in the correct direction. ~ Run the rudder hard over to both sides. Control that the rudder moves without any obstructions and that maximum rudder angle is obtained. adjust electrical end stoppers, if necessary. - Half the total rudder angle is the correct center position. Adjust both the mechanical and the electrical rudder indicators according to this 0-point. Control that the steering handles and the rudder indicators both show correct direction, ~ Check that the relief valve opens at maximum specified pressure, by pushing the emergency push-buttons on the solenoid valve until the rudder is in hard-over position. To obtain correct pressure, adjust relief valve (See instructions) . ~ Test the start and stop switches. - Test the alarm panel (See instructions) . SEA TRIAL ~ Check that these items are within the limits of the specification for the supplied steering gear, using both one and two pumps; - Steering time 35 - 0 - 30 deg. > Max. working pressure. Please fill in the form on the next page. 23SEATRIAL DATA Please fill in this form during the sea trial and send it to our head office for later reference. Address: ULSTEIN FRYDENBO AS P.O.BOX 3722 N 5033 FYLLINGSDALEN NORWAY Name of ship;.... Shipyard: . Hull no Owner: . Speed:.........knots Stb. Port Both pump pump — pumps Steering time 35-0-30 degrees: (seconds) ..... ooo Max pressure during steering: (bar) wwe. Max amps on el.motor during steering: (amp) ..... 22... vs... Comments: 24SECTION 3 MAINTENANCE INSTRUCTIONSECTION 3.0 SERVICE LOCATIONS: NORWAY: ULSTEIN FRYDENBO AS JONSTADVEIEN 6 N 5033 FYLLINGSDALEN Tel: 47-55-166990 Fax: 47-55-161790 Telex: 42236 FRYBO N THE NETHERLANDS: REKAB GRONINGEN B.V. KONINGSWEG 21 9731 AN GRONINGEN Tel: 31-50-425425 ° Fax: 31-50-425588 Telex: 53042 GERMANY: WALTER GRATSCH SCHWARTMOORALLEE 19 2085 QTCKBORN Tel: 49-41-0660685 Fax: 49-41-0681271 Telex: 2180663 U.S.A.: NAVCON INC. 111 WATER POINTE LANE SMITHFIELD, VA 23430 Tel: 1-804-3650971 Fax: 1-804-3650873 JAPAN: JAPAN HAMWORTHY & CO.LTD. PARK OMODATA 1A, 1-15, 1-CHOME, SHIGINO-NISHI, JOTO-KU, OSAKA 536 - JAPAN Tel: 06-962-8877 Fax: 06-962-8899 Telex: 529-3315 JAHAN J 26SECTION 3.1 MAL ICE_REPORTIN( It is requested that any failures or maintenance work on the equipment, no matter how small, should be reported to Frydenbo- Mjelner. By reporting any failures and maintenance work, an accurate machinery history can be maintained. This history will be contimuously monitored and compared to other vessels with similar equipment. With this information, we can provide better service, faster delivery ‘of spare parts, and guidance for preventive maintenance. When reporting, the following information should be included: 1) Date 2)’ Vessel name 3) Date of installation - order number 4) Operating hours (if available) 5) Description of problem 6) Did the problem impair vessel’s operation 7) Corrective action taken 8) How many manhours were required to repair it In reporting a failure or request for service, the following additional information is requested in addition to items 1-8 above. This will insure more efficient service. 9) Working and idling pressures 10) Steering time, 35-0-30 degrees. 27SECTION 3.2 MAINTENANCE If a hydraulic system is properly installed, started up and maintained, it will have a long life and run reliably. If problems do occur, however, it is essential to find the cause and put it right as quickly as possible. The FAULT FINDING CHART must be seen as a general fault finding guide only. Also use the hydraulic diagram if problems occur, as this will facilitate the fault finding. The service personnel of Ulstein Frydenbs AS has long experience in, the service and maintenance of hydraulic steering gears. This experience in the maintenance and service sectors is at the Gisposal of our customers. Contact our service department for guidance, or, if necessary, ask for a service engineer to be sent. IF PROBLEMS OCCUR, USE THE FAULT FINDING CHART. IF THE PROBLEM CANNOT BE SOLVED BY YOUR MAINTENANCE MEN, CALL IN A FRYDENBO SERVICE ENGINEER. 28SECTION 3.3 PERIODICAL MAINTENANCE PE The actuator should regularly be visually inspected for external leakage, paintwork, damages etc. A clean actuator will facilitate the inspection work. A continuous undisturbed functioning of the steering gear is dependant on two simple point: 1. Use the specified hydraulic oil 2. Keep the hydraulic system clean The hydraulic oil and the interior of the installation should be kept absolutely free from any impurities and air. If these points are adhered to the preventive maintenance will be limited to following: Yearly. A. Oil strainer in the pump unit to be opened and cleaned. Stuffing glands on the actuator to be checked. Every second year. B. Change hydraulic oil. A. Oil strainer. After the first 200 hours running, the oil strainer should be opened for inspection and cleaning. If you find impurities, cleaning of the filter mst be repeated at short intervals until it stays clean. This indicates that the hydraulic system is clean and the filter should now be left for the yearly routine inspection. The hydraulic pump shaft seal. Oil may leak froma worn seal, but a leaky seal may also allow air to be sucked into the system causing the oil to overflow the expansion tank. When leaking or worn, the seal must be renewed. The hydraulic pump The hydraulic pump will normally last more than 10 years. A worn pump should be replaced or repaired by fitting a new pump cartridge. A worn pump means reduced pumping capacity indicated by slower steering speed. D. The actuator The rotor seals and the gland seals are practically the only wearing parts. Wear on the rotor seals is indicated by unintended movement (creeping) of the rudder when at sea. Based on experience, the normal life time of the rotor seals is 5 to 10 years. For change of rotor seals, see instructions P p 29PE SECTION 3.4 CLEANING THE STRAINER OF THE PUMP UNIT (See assembly dwg.) 1. Shut off the expansion pipeline, see general arrangement drawing, by closing the shut-off valve. 2. Drain the oil by removing the drain plug item 16 in bottom of the pump housing. Some of the impurities will be removed with oil. The oil should not be reused. 3. Remove cover item 6, membrane item 5 and bump plate item 4. Lift out the strainer item 3. Clean all parts and inside of the pump housing. Use clean rags (not cotton waste) and rinse in gas oil. Assemble parts in the following order 5. Drain plug. 6. Strainer. 7. Bump plate 8. Membrane, replace if necessary. 9. Cover 10. Open the expansion line. 11. Open the vent-screws on the pump unit. The pump housing is then filled with oil and air will escape through the vent plugs The steering gear is now ready for trial. After the trial, open the vent screws to ascertain that the system is completely free from air (See "Filling of oil and venting procedure", section2.2) . 30SECTION 4 REPAIR INSTRUCTIONOG FULT 3536 Jay TPS ION FO SST | ABST POOPISRG FASST PO —Toaay AvpST WIjo PUD IOFOU|S HSU g Toda3y SINOS IS OHT OF PHI | 61|—| |) FOLOUEEGIg FOCOERG JO TyiAnIsUas aNssaI%: a Capes TouIoU si Gund ate Tuo Uy sos Hy 40 scart ony SIUBIZT “BUpAy-109 clare ARN dun 349-31 o6 e — 35 }G3-/7TOCRY. OE ORS T YORMS FAAS] FO HSUT_[ ST Tse PIO -soOyEST OGRE TJanay VO HOYT BUaD Te S500) 51 BUT BUT "Fo_WoN-s} jusus}s Cuyaiey, “Gund — FOU FUTON HIST "YAO sons] uoas 47 oyS—CuAG BAT 3 ér 2 TT BANG=ISNO U9TT SOY WHEE | OT é z Z x £ JaIF VOT PoUoop Jags aes ay ae a reo hak Spe eae $ seas ee i ear ee a ee ee 7 = SSE EET Io nO a ea ae Sv oR Bae a ese} | —— ag ae PS : ja a | — prea SHE ee PD a NOLL: . SLING SCEGREEEGI [sfaf [= See FeRee| AR PEEP RRRRER Gee tel PECEEPERCEERPR EBS EPERRS RICE eer ces LYVHD ONIGNIT 1 INV4 BT RFREERER SE Ske P] BPP eRe l Shee aes FPR] egal et 3 AT] Sages) = als WIULSAS AVID INIATIUS gis SY OENFMAAS NIUSTN IST HY. IIVSISO. 32swe SECTION 4.1 REPLACEMENT OF THE ACTUATOR SEALS (See fig. 1.) GLAND SEALS. er gland seals. (Item 5). Remove the upper gland ring. Remove the old gland seals. Grease new seals, before they are inserted, and also Apply grease before replacing gland ring. land seals Tt 6). Same procedure as for the upper seals. To facilitate reassembling of the lower gland ring, we recommend to lower the gland ring by means of two lengthened screws. The seals to be cut apart for inserting around rudderstock and to be glued together (Use LOCKTITE superglue no. 495). FIG. 1. IMPORTANT All seals are supplied in correct lengths and must NOT be shortened. The correct way of inserting the gland seals is shown in fig. 2. PRESS PRESS PRESS alSECTION 4.1 REPLACEMENT OF ACTUATOR SEALS. (Continued) (See fig.1.) INTERNAL SEALS: The following seals may be replaced without disconnecting the rotor from the rudder stock: Cover ring seal - item 1 Vertical stopper seals with springs - item 2 Vertical vane seals with springs - item 3 Top vane seals - item 4 The following seals can be replaced only when the rotor has been dismounted from the rudder stock: Lower vane seals - item 4 Bottom ring seal - item 1 - Drain the actuator for hydraulic oil through the bottom drain holes. ~ Nake sure that the vent plugs are open. - Remove the actuator cover. - Inspect actuator and cover. Clean, use rags. Replace seals in this order: A. When rotor has been dismounted from rudderstock and lifted out of the housing: 2, Bottom ring seal 2. Lower vane seal After the rotor has been lowered in to the housing: 3. Vertical vane seals with springs 4. Vertical segment seals with springs 5. Top vane seals 6. Cover ring seal B. When rotor is still attached to rudderstock: 1. Cover ring seal 2. Vertical vane seals with springs 3. Vertical segment seals with springs 4. Top vane seals Note! Grease all new seals before assembly. Assemble the actuator and fill up with oil. (See oil filling procedure) . 34SECTION 4.2 CONTROL AND RI OF THE THRUST BEARINGS (See assembly dwg.) CONTROL OF THE THRUST BEARING: Close the shut off valves for the expansion pipes. Drain oil from the actuator. Remove the gland ring and gland seals. Remove the cover of the actuator. Be sure that the ruddershaft is aligned and is not bending. Use feeler gauge and check the clearance between rotor-vanes and bottom of housing; Min. clearance is 0,10 mm. CHANGE OF THE THRUST BEARING: Bone woran Drain oil from the actuator Remove the gland ring and ithe gland seals. Remove-the cover of the actuator. Dismount the rotor from the rudderstock, (see section 2.1). Important! Secure rudderstock. Remove the old bearing (splitted in 4) and mount the new ones. ; Attach the rotor to the rudderstock again, (see section 2.1). Assemble cover, gland seals and gland ring. Fill the actuator with oil and vent, (see section 2.2). The actuator is now ready for trial. 35SECTION 4.3 CONTROL. AND REPLA OF LINERS (See assembly dwg.) CONTROL OF THE LINERS: i. Remove the upper and lower gland rings and gland seals. 2. Use feeler gauge and control that clearances between the xotor and the liners, A and B, are within limits. Be sure that the rotor is in center. + The clearances in the liners can be checked by removing the cover. Mechanical contact between the rotor and the housing, gover or stoppers, indicates too big clearances. It can also indicate that the actuator and rudderstock are out of line. This should be checked. REPLACEMENT OF THE LINERS: : Close the shut off valves for the exp. pipes, (see arr.dwg) . Drain oil from the actuator. + Remove the gland ring and the gland sealings. Remove the cover. Dismount the rotor from the rudderstock (see section 2.1). + Lower the rudderstock or loosen the foundation bolts and lift the actuator off the rudderstock. 7. Press out the old liners. 8. Fit the new liners. (Freeze if necessary) . ®. Check the inner diameter of the replaced liners, and the outer Giameter of the "rotorneck" to control that the clearances, A and B, are within limits. If not, grind the inner surfaces of the liners. 10.Put the rudderstock and/or the actuator back in position. 21.Attach the rotor to the rudderstock again (See section 2-1). 12.Fit cover, glandseals and glandrings. 23.Fill actuator with oil and vent (See section 2.2) 14 The steering gear is now ready for sea trial. aueune 36SECTION 4.4-1 THE PUMP UNIT - CHANGE OF THE MEMBRANE PE 12992, item 9.) 1. Shut of the expansion pipeline by closing the shut off valves under the expansion tank (see arr. dwg.) 2. Drain the oil by removing the drain plug, item 12, at the bottom of the pump unit. 3. Remove the end cover, item 10, and the old membrane, item 9. 4, Insert the new membrane and assemble the end cover and the drain plug. 5. Open the shut off valves of the expansion line. 6. Open the vent screw. The pump housing is then filled with oil and air will escape through the vent plugs. (See venting procedure, section 2.2). SECTION 4.4-2 TEE PUMP UNIT - CHANGE OF STIC RING! (Dwg. 32846, item 6.) 1. Unscrew the hexagon head screws, item 8. 2. The pump unit to be withdrawn and the elastic ring, item 6, removed 3. The new elastic ring to be inserted, and the pump unit replaced. . 4. After renewal of the elastic ring, the pump unit must be accurately aligned. SECTION 4.4-3 THE PUMP CARTRIDGE -CHANGE OF THE BALL BEARING (Dwg. 42895 - Part no. 34.) 1. Unscrew the hexagon screw, item 110, and remove the seal cover, item 9. 2. The shaft sealing-housing/bearing-housing, item 5, to be withdrawn after the fixing bolts have been unscrewed. 3. Circlips and washers, item 35 and 36, to be removed. 4. The ball bearing, item 34, to be withdrawn from the shaft. 5. Insert the new ball bearing on the shaft. Insert supporting washers and the circlips, iteni 36 and 35. 6. Assemble the shaft sealing-housing/bearing-housing and the seal cover, and tighten the bolts. SECTION 4.4-4 THE PUMP CARTRIDGE - CHANGE OF T SEAL RING (Dwg 42895 - Part no.107.) 1. Unscrew the hexagon screw, item 110, and remove the seal cover, item 9. 2. The shaft sealing-housing/bearing-housing, item 5, to be withdrawn after the fixing bolts have been unscrewed. 3. The old shaft seal rings, item 107, to be removed. 4 . Insert the new shaft seal rings. Important Do not forget to insert the supporting ring, item 108, in correct position. 5. Assemble the shaft sealing-housing/bearing-housing and seal cover, and tighten the bolts. 3FSECTION 5 DRAWINGSSECTION 5.0 DRAWING LIST General arrangement Rudder actuator - assembly Partlist for assembly, actuator Safety relief valve 2" Automatic Lock valve Pump unit type PE 2 Pump unit - assembly Control valve for pump unit Pump cartridge Expansiontank 39 Drawing no 13292 12927 80324 23317 44259 32846 / P30325 12992/ P80064 23130 42895 23585EE ee | | aT | SSS Se —— = —H aan it aavauor chs ‘VOT TAO TAVROTIZad ine gl (8 SE I ee | | = i a. x VY Uy 0) ah ® t& a FEN ma Wen eS |Printed 15.02.96 PARTLIST Name: [ACTUATOR HS 280-03 List no: | Peos2a Ref. drawing no] 12027 13078 13313 13295 444299 2.226758 2.32128 2.32127 2.32191 2.32668 2.32669 2.32670 123317 241601 2.23315 423315 2.44347 2.44221 2.41142 2.40429 2.44206 GE 16-SR 4.32666 4.32195 80378 aati SNOR-1 SNOR-1 400-025 400-024 3262-371 3262-379, 3261-362 ROTORHOUSING COVER ROTOR 2x37,5 LOCKVALVE 2" WISAE W.FLANGE LINER UPPER BRASS GLAND LOWER GLAND UPPER HATCH HS 120-~180 HATCH HS 120-180-280-03 HATCH HS 120-180-280-03 | HATCH HS 120-180-280-03 SAFETY VALVE PRESSURE VALVE BRACKET FOR RUDDER ANGLE SC RUDDER ANGLE SCALE POINTER HS 120/180/280-03 DISTANCE PIECE PLUG 1/2" BSP | PLUG 1 1/4"BSP. | VENT. PLUG 1/4" BSP PIPE FITTING GASKET GASKET HS 120/180/280 INTERNAL SEALS FOR ACTUATOR ‘O-RING GLAND CORD 14" CORD 1/4" BONDED SEAL 1/2" BSP BONDED SEAL 1/4" BSP HEX. HEAD SCREW M12X16 HEX. HEAD SCREW M12x40 HEX, HEAD SCREW M10X120 ULSTTEIN a ULSTEIN FRYDENBO AS Page 1 of 2Printed 18.02.96 PARTLIST 3261-781 HEX. HEAD SCREW M30X110 2.44286 EXTRACTING SCREW 3241-790 CYL. HEAD SCREW M30X160 2.44334 ADJUSTING SCREW 2.42140 PLUG 1" BSP WITH 1/4” HOLE 400-030 BONDED SEAL 1" BSP 400-032 BONDED SEAL 1.1/4" BSP | 202-738 | O-RING 64,50 x 3,00 | | ULSTEIN ULSTEIN FRYDENBO AS Page 2 of 2TT i . A 5 MM i a pepe [I = la SS ee ze aR RSENS Pha ¥ | A e z| de! : a Seeks 4 ve REREEAE = Bs =950_, 2 | SAE FLANGE 7 AS10875 3000 PSI BS IST Ci, HEAD SCREW © | SHI-379__| M240 NS 3735 12.9 21 O-RNG 745 x 30 | 5 | 202-740 4 Z| O-RNG 5675 x 553 | 3 | 200-208 a 2 LOOK VALE" 1 LOCK VALVE 2” ASSEMBLY seem [aun] ovoret a] | WITH SAE-FLANGE i | Tiherer Z SS. Ala ULSTEIN FRYDENBO as Wi i itl? saad CT Py 44299_ SV QENAGAUS NIBLSIN «2 3d LINN dd daMOd NMOHS ONVH LHOWY JdAL ONVH LHI ONY L4F7 AVES GATT BONYI BINSS Fed ININVONNS TW SISIAS 90 SISSVAI IDTWMOTIN ALVIdCIS OL GIGI ONY OUdVOV 38 OL 3DId-1004Printed 15.02.96 PARTLIST POWER PACK PE" - SNE2BOERA6R 80325 32846 Part name PUMP UNIT PE2™ EL. MOTOR SIEMENS 180L FOUNDATION 'P80064 818344252 423495 [4 | | 42848 ‘SPIDEX 42/55 BORED 48MM |; 42K _|_NYLON RING COUPLING 42/65 [8 9514251300 | PLUG CONNECTOR WIRECTIFIER | 2 gE100074 SOLENOID VALVE BOSCH 96V___ 3262-476 | HEX. HEAD SCREW M16x50__ 3262-475 HEX. HEAD SCREW M16X50 3241-208, | CYLHEAD SCREW M5X30 21407-1 | GUARD PLATE 3262-239 | HEX. HEAD SCREW M6X10 | I } 7 42432 | SPIDEX 42/55 BORED 32MM | 3451-218 | WASHER M6 ULSTEIN ULSTEIN FRYDENBO AS Page 1 of 14seg : 533] a © 2 uous anv sho aus ane NOW LaPrinted 15.02.96 PARTLIST | PUMP UNIT PED | Pa006e | 08.03.85 2 12063-280 1.0 ‘SNE280ER46R 1.0 3262-475 HEX. HEAD SCREW M16X50 6.0 2.31092 STRAINER PE2" SNE 120-280 4.0 2.42027 BUMP PLATE PE 2" 10 2.30428 1.0 123130 CONTROL VALVE PE 2" 40 2M5/162-3, PLUG 1" BSP 10 2.44208 VENT. PLUG 1/4" BSP. 10 400-030 BONDED SEAL 1" BSP 2,0 400-021 BONDED SEAL 1/4" BSP 1.0. 200-340 O-RING 85,10X 5,34 3.0 3241-381 CYL HEAD SCREW M12X50 ‘| 60 3262-381 HEX. HEAD SCREW M12X50 12,0 200-251 O-RING 129,70 X 3,53 (R-4512) 2,0 | | | | | | GE 28-LR PIPE FITTING 1,0 | ULSTEIN ULSTEIN FRYDENBO AS Page 1 of 1TEA . iL | CE ral | “Sara - echt ser mat E agit mae omer ae F ane a Baas | ae F wet - ARE ISO f f aete| 7 OE aS le ears parr = r —— eae tor ome e| = arises Esi/sn | a Sills |e |— SE SSPE ARS OH WI | 5) SLE SH 09910 | ee AES O2 e ‘ee ;}——_____}s2 |" 5/77 [e | = wate ast eee ETOH pe ez | aoe bE : weneer eae i = if eae LEGGEALLWEILER PUMP CARTRIDGE TYPE SNE 280ER 35 heel 48 107 110 ( 4 ie Part No, Denomination 5 | SHAFT SEALING HOUSING / BEARING HOUSING 9 | SEAL COVER 34 | GROOVE BALL BEARING 6208 J 35 | CIRCLIP 36 | SUPPORTING WASHER 107 | SHAFT SEAL RING BA, U3. 49x 60x10 106 | SUPPORTING RING 60x 40.269 110| HEXAGON SCREW 42895=e 02 EL voce EE [oe menn | WE LAS BO fa] S21) SULIT 09 “WNL NOISWVGIXD sear set | os t T TIM ang OL a — eee 7 3/8 i an | any a O © ry a le n Ey th r ote a ot =SECTION 6 PARTS CATALOGUE, ULSTEIN FRYDENBO AS SPARE PARTS FOR STEERING GEAR- ACTUATOR AND PUMP UNIT YARD: FLENDER WERFT DATE: 29.01.95 ‘Steering gear type HS 280 D Tall wo 66146624 665+666+667 Page 1 of 1 ORDER NO: 6303463044 6344+634546346 Pos | DwG. NO. gry. | PART DESCRIPTION 01 | 12927 1 | SEALING corD @ 1/4" 02 SET OF GLAND SEALING RINGS 03 05 06 07 08 os 10 1 12 13 14 5 16 41